US4971726A - Electroconductive resin composition - Google Patents
Electroconductive resin composition Download PDFInfo
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- US4971726A US4971726A US07/213,264 US21326488A US4971726A US 4971726 A US4971726 A US 4971726A US 21326488 A US21326488 A US 21326488A US 4971726 A US4971726 A US 4971726A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/24—Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
- H01R13/035—Plated dielectric material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/003—Filling materials, e.g. solid or fluid insulation
Definitions
- the present invention relates to an electroconductive resin composition exhibiting a high and stable electroconductivity which contains a small filling amount of a specific carbon black and graphite combination as the electroconductive filler which is used to fill a thermoplastic resin and/or a thermosetting resin.
- Plastic moldings are frequently used as casings of these electronic instruments to cope with the demands for a lightweight, low cost, mass-produced article, etc., but these plastic moldings do not have a shielding effect against electromagnetic waves, and thus cannot solve the above problem.
- an electroconductive resin comprising an electroconductive filler which is filled and dispersed in a resin.
- an electroconductive filler a metal type filler and a carbon type filler are generally employed.
- a metal type filler is suitable for imparting a high electroconductivity, but has drawbacks in that the specific gravity thereof is high, the electroconductivity is reduced the losses occurring due to filler cutting during molding, and the metal type filler causes abrasion of the extrusion screws and molds.
- a carbon type filler such as carbon black or graphite will not substantially abrade extrusion screws or molds, but it is not suitable for uses in which a high electroconductivity with a volume resistivity value of 1 ⁇ cm or less is required, such as electromagnetic shielding materials, electrodes, etc.
- electroconductive carbon blacks a small amount of Ketjen Black EC (produced by Ketjen Black International) can provide a satisfactory electroconductivity, but the mechanical strength of the composition is remarkably worsened and the resultant material is very brittle and easily destroyed.
- Graphite itself has a good electro-conductivity, but when dispersed in a resin, a high electroconductivity can not be obtained unless a large filling hereof is used, and further, a problem arises in that the resistance value has a great amplitude of 10 1 to 10 -1 ⁇ cm, and a stable electroconductivity cannot be obtained (Japanese Unexamined Patent Publication (Kokai) No. 60-118744). Further, when carbon black and graphite are used in combination, although a high electroconductivity can be obtained from a low filling amount, the mechanical strength of the composition is lowered and the moldability reduced.
- the objects of the present invention are to eliminate the above-mentioned disadvantages of the prior art and to provide an electroconductive resin composition having a stable and high electroconductivity when a small filling amount of an electroconductive filler is formulated therein, and which has an excellent mechanical strength, kneadability, and moldability properties.
- an electroconductive resin composition comprising (i) 100 parts by weight of at least one resin selected from the group consisting of thermoplastic resins and thermosetting resins and (ii) 15 to 150 parts by weight of (a) carbon black having a DBP oil absorption amount of 400 ml/100 g or more and (b) expanded graphite having an average particle size of 40 ⁇ m or more, wherein the expanded graphite content is 40 to 90% by weight of the total amount of the carbon black and the expanded graphite.
- the present inventors previously proposed a composition having a high electroconductivity even at a filling amount of about 80%, compared with a carbon black of the prior art, for example, Ketjen Black EC (DBP oil absorption amount: 325 ml/100 g) by using a specific carbon black with a DBP oil absorption amount of 400 ml/100 g or more (Japanese Unexamined Patent Publication (Kokai) No. 60-8335).
- DBP oil absorption amount 325 ml/100 g
- a special graphite was used in combination with the special carbon black, to obtain an electroconductive resin composition having a high electroconductivity at a filling amount of about 60%, compared with the carbon black and graphite of the prior art, and consequently, having a lower cost and an improved specific gravity, and having excellent kneadability and mechanical strength properties.
- the carbon black usable in the present invention has a DBP oil absorption amount of 400 ml/100 g or more.
- a larger amount of carbon black must be formulated to obtain a resin composition with a high electroconductivity, and thus the mechanical strength is impaired.
- the upper limit value of the DBP oil absorption amount is not particularly limited, when this amount is more than 700 ml/100 g, the dispersibility of carbon black in the resin is reduced, and therefore, preferably the DBP oil absorption amount is in the range of 400 to 600 ml/100 g.
- the term "DBP oil absorption amount" used in the present specification means the oil absorption amount defined according to ASTM D2414-79.
- the expanded graphite usable in the present invention can be prepared by treating natural or artificial graphite with, for example, an inorganic acid such as sulfuric acid, nitric acid, etc., to form graphite interlayer compounds, washing the compounds with water followed by dehydration, abruptly heating and expanding the compounds, and compressing the resultant expanded graphite into a sheet or mass followed by mechanical pulverization thereof, by means of a Henschel mixer, hammer mill, ball mill, etc., to a particle size of 40 ⁇ m or more.
- an inorganic acid such as sulfuric acid, nitric acid, etc.
- the upper limit value of the particle size of the expanded graphite is not particularly limited, but if the size is 5 cm or larger, kneading becomes undesirably difficult, and therefore, in the present invention, the range of the particle size is preferably from 40 to 20,000 ⁇ m.
- the amounts of carbon black and expanded graphite used with the present invention are 15 to 150 parts by weight, preferably 20 to 130 parts by weight, based on 100 parts by weight of the thermoplastic and/or thermosetting region. At an amount lower, a high conductivity of 1 ⁇ 10° ⁇ cm or lower can not be exhibited, and at an amount higher, kneading becomes impossible.
- the ratio of the carbon black to the graphite to be used in the represent invention may be 40 to 90% by wight, preferably 45 to 85% by weight, for the graphite based on 100% by weight of the total amount of the carbon black, and the graphite.
- the graphite content excess 90% by weight the electroconductivity is lowered, and at a content lower than 40% by weight, although the electroconductivity is good, the mechanical strength is lowered, and thus the object of the present invention tends to be difficult to be achieved.
- thermoplastic resins and thermosetting regions usable in the present invention include various types known in the art and are not particularly limited. Specific examples may include thermoplastic resins such as low, medium and high density polyethylenes, linear low density polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, acrylonitrile-butadiene-styrene ternary copolymer, polystyrene, acrylonitrile-styrene copolymer, nitrile rubber, butadiene rubber, styrene-butadiene rubber, ethylene-propylene-diene rubber, silicone rubber, thermoplastic polyurethane resin, polyamide resin, polyester resin, polycarbonate, polyvinyl chloride, polyacetal resin, polyphenylene sulfite, polyphenylene oxide, etc. Examples of the thermosetting resins may include thermosetting acrylic resins, phenol resins, unsaturated
- the electroconductive resin composition of the present invention may further contain additives such as antioxidants, heat-resistant stabilizers, lubricants, flame retardants, pigments, plasticizers, cross-linking agents, UV-ray absorbers, reinforcing agents, etc., which are conventionally used in thermoplastic resins.
- additives such as antioxidants, heat-resistant stabilizers, lubricants, flame retardants, pigments, plasticizers, cross-linking agents, UV-ray absorbers, reinforcing agents, etc., which are conventionally used in thermoplastic resins.
- composition of the present invention can be prepared according to any known method, but preferably is molded into pellets by mixing and kneading uniformly in a conventional manner by a suitable blender such as a kneader, Banbury mixer, mixing rolls, pressure kneader, etc., and these pellets are molded into a desired product by press molding, extrusion molding, injection molding, sheeting, blow molding, etc.
- a suitable blender such as a kneader, Banbury mixer, mixing rolls, pressure kneader, etc.
- a resin composition with a stable and high electroconductivity can be obtained at a low filling amount of carbon black and graphite, and therefore, is highly electroconductive compared with the resin composition of the prior art, and has excellent mechanical strength and moldability properties with a lower specific gravity.
- the electroconductive resin composition of the present invention can be applied to various fields, and can be utilized not only in electromagnetic wave shielding materials, but also, for example, as an electroconductive material for high voltage cables, ignition cables, plane heat-generating members, plane switches, electrodes, etc., or for applications such as electronic instruments or IC package materials, as a material for molded video discs, and as a permanent antistatic material, etc.
- the present invention will now be further illustrated by, but is by no means limited to, the following Examples.
- the electroconductivity in the Examples was evaluated in terms of the volume resistivity value according to the measuring method of SRIS 2301 of the Rubber Society of Japan, the electromagnetic shielding effect was measured by both a TR-4172 and a shielding box produced by Advantest K. K., and the shielding was evaluated at a shielding of 300 MHz in the electrical field.
- the mechanical strength of the composition was evaluated by the Izod impact strength value obtained by the method of JIS-K-7110, and the specific gravity of the composition was measured according to the method of JIS-K-7112.
- a polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H), carbon black and/or the various graphites as shown in Table-1 were formulated in the respective predetermined amounts, kneaded by a Laboplastomill at a temperature of 200° C., and then press molded into a plate 15 cm square with a thickness of 2 mm.
- the volume resistivity value hereinafter abbreviated as VR
- the shielding effect of the obtained molded product were measured, and the results thereof are as shown in Table 1, in relation to each electroconductive resin composition.
- the VR is about 5 ⁇ 10 -2 ⁇ cm and the shielding effect was good at about 70 dB and stable with little amplitude of the value, thus having a superior shielding effect by about 15 dB and an about 4-fold VR, compared with the use of a carbon black and graphite other than those of the present invention (see Experiments No. 9-13), even at the same filling amount.
- a polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H) was formulated with the carbon black and various types of graphite shown in Table 2 so that the molded plate exhibited a VR of about 1 ⁇ 10 -1 ⁇ cm, and kneaded and molded according to the same method as described in Example 1.
- the VR, Izod impact strength and specific gravity of the molded plate obtained were measured, and the results are shown in Table 2 in relation to each electroconductive resin composition.
- the filling amount may be about 60% by weight, compared with that when employing a carbon black and graphite other than that of the present invention, whereby the Izod impact strength can be improved and the specific gravity reduced.
- a 100 parts by weight amount of a high density polyethylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: 520 (B) was formulated respectively with predetermined amounts of a carbon black with a DBP oil absorption amount of 480 ml/100 g and an expanded graphite with an average particle size of 500 ⁇ m, kneaded by a Laboplastomill at a temperature of 180° C., and press molded according to the same method as in Example 1.
- the VR, the shielding effect, and the Izod impact strength of the molded plate obtained were measured, and the results are shown in Table 3 in relation to each electroconductive resin composition.
- a 70 parts by weight amount of a polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H), 9 parts by weight of a carbon black with a DBP oil absorption amount of 480 ml/100 g and 21 parts by weight of an expanded graphite with an average particle size of 500 ⁇ m were added with additives for resins such as antioxidants for resins, UV-ray absorbers, flame retardants, reinforcing agents, lubricants, etc., shown in Table 5, and kneaded and molded according to the same method as in Example 1.
- the VR and the shielding effect of the molded products obtained were measured, and the types and amounts of the additives for resins employed, and the measurement results, are shown in Table 5.
- thermoplastic resin, carbon black having a DBP oil absorption amount of 480 ml/100 g, expanded graphite, antioxidants for resins, flame retardants, reinforcing agents, lubricants, and plasticizers listed in Tables 6 and 7 were formulated in an amount shown in Tables 6 and 7.
- the mixture was kneaded and molded in the same manner as in Example 1.
- the VR and the shielding effect of the molded products obtained were measured. The results are shown in Tables 6 and 7 in relation to the composition of the electroconductive resin.
Abstract
An electroconductive resin composition contains (i) 100 parts by weight of thermoplastic resins and/or thermosetting resins and (ii) 15 to 150 parts by weight of (a) carbon black having a DPB oil absorption amount of 400 ml/100 g or more and (b) expanded graphite having an average particle size of 40 mu m or more, wherein the expanded graphite content is 40 to 90% by weight of the total amount of the carbon black and the expanded graphite.
Description
1. Field of the Invention
The present invention relates to an electroconductive resin composition exhibiting a high and stable electroconductivity which contains a small filling amount of a specific carbon black and graphite combination as the electroconductive filler which is used to fill a thermoplastic resin and/or a thermosetting resin.
2. Description of the Related Art
Remarkable developments have and are occurring in the field of electronic machines such as computers, VTR, acoustic instruments, home appliances, word processors, etc. In these electronic instruments, due to the high integration density of electronic circuits and devices thereof, microcurrents are used, and thus a problem arises in that an erroneous actuation, etc., may be caused by electromagnetic waves from an external source.
Plastic moldings are frequently used as casings of these electronic instruments to cope with the demands for a lightweight, low cost, mass-produced article, etc., but these plastic moldings do not have a shielding effect against electromagnetic waves, and thus cannot solve the above problem.
In the prior art, as a method for imparting an electromagnetic wave shielding property to plastic moldings, an electroconductive resin has been proposed comprising an electroconductive filler which is filled and dispersed in a resin. As the electroconductive filler, a metal type filler and a carbon type filler are generally employed.
A metal type filler is suitable for imparting a high electroconductivity, but has drawbacks in that the specific gravity thereof is high, the electroconductivity is reduced the losses occurring due to filler cutting during molding, and the metal type filler causes abrasion of the extrusion screws and molds.
A carbon type filler such as carbon black or graphite will not substantially abrade extrusion screws or molds, but it is not suitable for uses in which a high electroconductivity with a volume resistivity value of 1 Ω·cm or less is required, such as electromagnetic shielding materials, electrodes, etc. Among electroconductive carbon blacks, a small amount of Ketjen Black EC (produced by Ketjen Black International) can provide a satisfactory electroconductivity, but the mechanical strength of the composition is remarkably worsened and the resultant material is very brittle and easily destroyed. Graphite itself has a good electro-conductivity, but when dispersed in a resin, a high electroconductivity can not be obtained unless a large filling hereof is used, and further, a problem arises in that the resistance value has a great amplitude of 101 to 10-1 Ω·cm, and a stable electroconductivity cannot be obtained (Japanese Unexamined Patent Publication (Kokai) No. 60-118744). Further, when carbon black and graphite are used in combination, although a high electroconductivity can be obtained from a low filling amount, the mechanical strength of the composition is lowered and the moldability reduced. Therefore, when a highly electroconductive resin composition is obtained by using the carbon black and graphite of the prior art, molding becomes difficult and the resin composition obtained has a lowered mechanical strength, particularly a lowered impact strength, and since carbon black and graphite are more expensive and have a higher specific gravity than the resin, a composition obtained by using these fillers is disadvantageous both in terms of having a high cost and in that it is heavy. To improve the moldability, a method has been proposed in which a propylene-ethylene copolymer with a high binder efficiency is formulated (Japanese Unexamined Patent Publication (Kokai) No. 51-17937), and a method in which a resin-coated carbon black and a resin-coated graphite are employed (Japanese Unexamined Patent Publication (Kokai) No. 61-218648), etc. However, these methods do not provide a reduction of the filling amount of carbon black and graphite, and thus did not provide a solution to the above problems. Accordingly, it is desirable that a carbon black and graphite which is capable of exhibiting a high electroconductivity even at a low filling amount, be produced.
Accordingly, the objects of the present invention are to eliminate the above-mentioned disadvantages of the prior art and to provide an electroconductive resin composition having a stable and high electroconductivity when a small filling amount of an electroconductive filler is formulated therein, and which has an excellent mechanical strength, kneadability, and moldability properties.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, there is provided an electroconductive resin composition comprising (i) 100 parts by weight of at least one resin selected from the group consisting of thermoplastic resins and thermosetting resins and (ii) 15 to 150 parts by weight of (a) carbon black having a DBP oil absorption amount of 400 ml/100 g or more and (b) expanded graphite having an average particle size of 40 μm or more, wherein the expanded graphite content is 40 to 90% by weight of the total amount of the carbon black and the expanded graphite.
The present inventors previously proposed a composition having a high electroconductivity even at a filling amount of about 80%, compared with a carbon black of the prior art, for example, Ketjen Black EC (DBP oil absorption amount: 325 ml/100 g) by using a specific carbon black with a DBP oil absorption amount of 400 ml/100 g or more (Japanese Unexamined Patent Publication (Kokai) No. 60-8335). As a result of further investigations, to accomplish the present invention, a special graphite was used in combination with the special carbon black, to obtain an electroconductive resin composition having a high electroconductivity at a filling amount of about 60%, compared with the carbon black and graphite of the prior art, and consequently, having a lower cost and an improved specific gravity, and having excellent kneadability and mechanical strength properties.
The carbon black usable in the present invention has a DBP oil absorption amount of 400 ml/100 g or more. When the oil absorption amount is less, a larger amount of carbon black must be formulated to obtain a resin composition with a high electroconductivity, and thus the mechanical strength is impaired.
On the other hand, although the upper limit value of the DBP oil absorption amount is not particularly limited, when this amount is more than 700 ml/100 g, the dispersibility of carbon black in the resin is reduced, and therefore, preferably the DBP oil absorption amount is in the range of 400 to 600 ml/100 g. The term "DBP oil absorption amount" used in the present specification means the oil absorption amount defined according to ASTM D2414-79.
The expanded graphite usable in the present invention can be prepared by treating natural or artificial graphite with, for example, an inorganic acid such as sulfuric acid, nitric acid, etc., to form graphite interlayer compounds, washing the compounds with water followed by dehydration, abruptly heating and expanding the compounds, and compressing the resultant expanded graphite into a sheet or mass followed by mechanical pulverization thereof, by means of a Henschel mixer, hammer mill, ball mill, etc., to a particle size of 40 μm or more.
The upper limit value of the particle size of the expanded graphite is not particularly limited, but if the size is 5 cm or larger, kneading becomes undesirably difficult, and therefore, in the present invention, the range of the particle size is preferably from 40 to 20,000 μm.
The amounts of carbon black and expanded graphite used with the present invention are 15 to 150 parts by weight, preferably 20 to 130 parts by weight, based on 100 parts by weight of the thermoplastic and/or thermosetting region. At an amount lower, a high conductivity of 1×10° Ω·cm or lower can not be exhibited, and at an amount higher, kneading becomes impossible.
The ratio of the carbon black to the graphite to be used in the represent invention may be 40 to 90% by wight, preferably 45 to 85% by weight, for the graphite based on 100% by weight of the total amount of the carbon black, and the graphite. When the graphite content excess 90% by weight, the electroconductivity is lowered, and at a content lower than 40% by weight, although the electroconductivity is good, the mechanical strength is lowered, and thus the object of the present invention tends to be difficult to be achieved.
The thermoplastic resins and thermosetting regions usable in the present invention include various types known in the art and are not particularly limited. Specific examples may include thermoplastic resins such as low, medium and high density polyethylenes, linear low density polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, acrylonitrile-butadiene-styrene ternary copolymer, polystyrene, acrylonitrile-styrene copolymer, nitrile rubber, butadiene rubber, styrene-butadiene rubber, ethylene-propylene-diene rubber, silicone rubber, thermoplastic polyurethane resin, polyamide resin, polyester resin, polycarbonate, polyvinyl chloride, polyacetal resin, polyphenylene sulfite, polyphenylene oxide, etc. Examples of the thermosetting resins may include thermosetting acrylic resins, phenol resins, unsaturated polyester resins, epoxy resins, urethane resins, alkyd resins, etc.
The electroconductive resin composition of the present invention may further contain additives such as antioxidants, heat-resistant stabilizers, lubricants, flame retardants, pigments, plasticizers, cross-linking agents, UV-ray absorbers, reinforcing agents, etc., which are conventionally used in thermoplastic resins.
The composition of the present invention can be prepared according to any known method, but preferably is molded into pellets by mixing and kneading uniformly in a conventional manner by a suitable blender such as a kneader, Banbury mixer, mixing rolls, pressure kneader, etc., and these pellets are molded into a desired product by press molding, extrusion molding, injection molding, sheeting, blow molding, etc.
According to the present invention, a resin composition with a stable and high electroconductivity can be obtained at a low filling amount of carbon black and graphite, and therefore, is highly electroconductive compared with the resin composition of the prior art, and has excellent mechanical strength and moldability properties with a lower specific gravity. Accordingly, the electroconductive resin composition of the present invention can be applied to various fields, and can be utilized not only in electromagnetic wave shielding materials, but also, for example, as an electroconductive material for high voltage cables, ignition cables, plane heat-generating members, plane switches, electrodes, etc., or for applications such as electronic instruments or IC package materials, as a material for molded video discs, and as a permanent antistatic material, etc.
The present invention will now be further illustrated by, but is by no means limited to, the following Examples. The electroconductivity in the Examples was evaluated in terms of the volume resistivity value according to the measuring method of SRIS 2301 of the Rubber Society of Japan, the electromagnetic shielding effect was measured by both a TR-4172 and a shielding box produced by Advantest K. K., and the shielding was evaluated at a shielding of 300 MHz in the electrical field. The mechanical strength of the composition was evaluated by the Izod impact strength value obtained by the method of JIS-K-7110, and the specific gravity of the composition was measured according to the method of JIS-K-7112.
A polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H), carbon black and/or the various graphites as shown in Table-1 were formulated in the respective predetermined amounts, kneaded by a Laboplastomill at a temperature of 200° C., and then press molded into a plate 15 cm square with a thickness of 2 mm. The volume resistivity value (hereinafter abbreviated as VR) and the shielding effect of the obtained molded product were measured, and the results thereof are as shown in Table 1, in relation to each electroconductive resin composition.
When graphite alone was used (see Experiments No. 14-16), even when filled in an amount of 60 parts by weight based on 100 parts by weight of the total amount of the resin and the graphite, the VR and shielding effect were poor, and the amplitude of the measured value was great. Also, even when the graphite of the present invention was used alone, only a VR and shielding effect substantially equal to that obtained when employing a graphite other than that of the present invention were exhibited. On the other hand, as understood from Table 1, when the carbon black and the graphite of the present invention were used in combination (see Experiments No. 1-8), the VR is about 5×10-2 Ω·cm and the shielding effect was good at about 70 dB and stable with little amplitude of the value, thus having a superior shielding effect by about 15 dB and an about 4-fold VR, compared with the use of a carbon black and graphite other than those of the present invention (see Experiments No. 9-13), even at the same filling amount.
TABLE 1
__________________________________________________________________________
Present Invention
Experiment No. 1 2 3 4 5 6 7 8
__________________________________________________________________________
Electroconductive resin
composition (wt. parts)
Polypropylene resin
57 57 57 57 57 57 57 57
DBP oil absorption amount
480 ml/100 g carbon black
13 13 13 13 13 0 0 0
420 ml/100 g carbon black
0 0 0 0 0 13 13 0
400 ml/100 g carbon black
0 0 0 0 0 0 0 13
325 ml/100 g carbon black*.sup.1
0 0 0 0 0 0 0 0
Graphite powder (average particle size)
Expanded graphite (2.8 μm)
0 0 0 0 0 0 0 0
Expanded graphite (4.2 μm)
0 0 0 0 0 0 0 0
Expanded graphite (40 μm)
30 0 0 0 0 0 0 0
Expanded graphite (70 μm)
0 30 0 0 0 30 0 0
Expanded graphite (500 μm)
0 0 30 0 0 0 0 0
Expanded graphite (5 mm)
0 0 0 30 0 0 30 30
Expanded graphite (10 mm)
0 0 0 0 30 0 0 0
Vein graphite (40 μm)
0 0 0 0 0 0 0 0
Artificial graphite (80 μm)
0 0 0 0 0 0 0 0
Volume resistivity value (Ω · cm)*.sup.2
6.3 ×
4.1 ×
3.8 ×
3.7 ×
3.8 ×
5.1 ×
4.7 ×
5.0 ×
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
6.7 ×
4.3 ×
3.9 ×
3.9 ×
3.9 ×
5.2 ×
4.9 ×
5.1 ×
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
10.sup.-2
Shielding effect in electrical field
67.2
70.1
70.3
70.4
71.2
69.9
70.2
68.8
of 300 MHz (dB)*.sup.2
68.5
72.1
72.2
72.3
72.3
70.8
71.0
69.8
__________________________________________________________________________
Comparative
Experiment No. 9 10 11 12 13 14 15 16
__________________________________________________________________________
Electroconductive resin
composition (wt. parts)
Polypropylene resin
57 57 57 57 57 40 40 40
DBP oil absorption amount
480 ml/100 g carbon black
13 13 13 13 0 0 0 0
420 ml/100 g carbon black
0 0 0 0 0 0 0 0
400 ml/100 g carbon black
0 0 0 0 0 0 0 0
325 ml/100 g carbon black*.sup.1
0 0 0 0 13 0 0 0
Graphite powder (average particle size)
Expanded graphite (2.8 μm)
30 0 0 0 0 0 0 0
Expanded graphite (4.2 μm)
0 30 0 0 0 0 0 0
Expanded graphite (40 μm)
0 0 0 0 30 60 0 0
Expanded graphite (70 μm)
0 0 0 0 0 0 60 0
Expanded graphite (500 μm)
0 0 0 0 0 0 0 0
Expanded graphite (5 mm)
0 0 0 0 0 0 0 0
Expanded graphite (10 mm)
0 0 0 0 0 0 0 0
Vein graphite (40 μm)
0 0 30 0 0 0 0 60
Artificial graphite (80 μm)
0 0 0 30 0 0 0 0
Volume resistivity value (Ω · cm)*.sup.2
1.8 ×
1.4 ×
1.8 ×
2.3 ×
1.0 ×
2.8 ×
1.9 ×
3.0 ×
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.0
10.sup.0
10.sup.0
2.0 ×
1.6 ×
2.5 ×
2.8 ×
1.2 ×
8.2 ×
6.3 ×
8.0 ×
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.0
10.sup.0
10.sup.0
Shielding effect in electrical field
51.3
53.2
49.1
46.2
56.0
6.2
9.5
6.3
of 300 MHz (dB)*.sup.2
52.4
55.5
52.3
49.3
59.0
19.3
23.7
18.2
__________________________________________________________________________
*.sup.1 Carbon black with DBP oil absorption amount of 325 ml/100 g is
Ketjen Black EC
*.sup.2 Volume resistivity value and shielding effect at electrical field
of 300 MHz was measured with 3 samples prepared with the same composition
and the upper limit value and the lower limit value measured are shown.
A polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H) was formulated with the carbon black and various types of graphite shown in Table 2 so that the molded plate exhibited a VR of about 1×10-1 Ω·cm, and kneaded and molded according to the same method as described in Example 1. The VR, Izod impact strength and specific gravity of the molded plate obtained were measured, and the results are shown in Table 2 in relation to each electroconductive resin composition.
From Table 2 it can be seen that, by using the carbon black and graphite of the present invention, when a VR of about 1×10-1 is exhibited, the filling amount may be about 60% by weight, compared with that when employing a carbon black and graphite other than that of the present invention, whereby the Izod impact strength can be improved and the specific gravity reduced.
TABLE 2
__________________________________________________________________________
Present Invention Comparative
Experiment No. 17 18 19 20 21 22 23
__________________________________________________________________________
Electroconductive resin
composition (wt. parts)
Polypropylene resin
65 67 71 70 52.4 53.3 58.7
Oil absorption amount
10.5 9.9 8.7 9.0 14.3 14.0 0
480 ml/100 g carbon black
Oil absorption amount
0 0 0 0 0 0 12.4
325 ml/100 g carbon black
Graphite powder (particle size)
Expanded graphite (4.2 μm)
0 0 0 0 33.3 0 0
Expanded graphite (40 μm)
24.5 0 0 0 0 0 28.9
Expanded graphite (70 μm)
0 23.1 0 0 0 0 0
Expanded graphite (500 μm)
0 0 20.3 0 0 0 0
Expanded graphite (5 mm)
0 0 0 21.0 0 0 0
Scale graphite (40 μm)
0 0 0 0 0 32.7 0
Volume resistivity value (Ω · cm)
9.1 × 10.sup.-2
9.7 × 10.sup.-2
9.8 × 10.sup.-2
9.9 × 10.sup.-2
9.5 × 10.sup.-2
9.7 × 10.sup.-2
1.1 ×
10.sup.-1
Izod impact strength (kg · cm/cm)
3.0 3.3 4.2 4.2 0.2 0.1 1.1
Specific gravity 1.14 1.12
1.10 1.09
1.25 1.25 1.20
Total amount of carbon black and
53.8 49.3 40.8 42.9 90.8 87.6 70.2
graphite based on 100 parts by weight
of polypropylene
__________________________________________________________________________
A 100 parts by weight amount of a high density polyethylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: 520 (B) was formulated respectively with predetermined amounts of a carbon black with a DBP oil absorption amount of 480 ml/100 g and an expanded graphite with an average particle size of 500 μm, kneaded by a Laboplastomill at a temperature of 180° C., and press molded according to the same method as in Example 1. The VR, the shielding effect, and the Izod impact strength of the molded plate obtained were measured, and the results are shown in Table 3 in relation to each electroconductive resin composition.
TABLE 3
__________________________________________________________________________
Present Invention Comparative
Experiment No. 24 25 26 27 28 29 30 31
__________________________________________________________________________
Electroconductive resin
composition (wt. parts)
High density polyethylene resin
100 100 100 100 100 100 100 100
DBP oil absorption amount
12.0 10.8 15 13 14.7 7.8 7.5 16
480 ml/100 g carbon black (A)
Expanded graphite
8.0 7.2 135 117 6.3 5.2 142.5 144
(average particle size 500 μm) (B)
Carbon black A/Expanded graphite
60/40 60/40 10/90 10/90 70/30 60/40 5/95 10/90
(500 μm) B
Volume resistivity value (Ω · cm)
2.0 × 10.sup.-1
9.0 × 10.sup.-1
3.5 × 10.sup.-2
4.2 × 10.sup.-2
2.3 × 10.sup.-1
8.0 × 10.sup.0
6.3
--*mes. 10.sup.
Shielding effect in electrical field
50.6 31.1 72.2
71.4
49.9 5.9 9.5 --*
of 300 MHz (dB)
Izod impact strength (kg · cm/cm)
3.0 8.2 1.5
2.0
0.2 10.5 1.0 --*
__________________________________________________________________________
*No sample preparation possible because kneading was impossible.
Different types of resins (70 parts by weight), 9 parts by weight of a carbon black with a DBP oil absorption amount of 480 ml/100 g and 21 parts by weight of an expanded graphite with an average particle size of 500 μm were kneaded and press molded at a temperature shown in Table 4, to obtain a plate 15 cm square having a thickness of 2 mm. The VR and the shielding effect of the molded plate were measured, and the types of resins, kneading, and molding temperatures employed, and the measurement results, are shown in Table 4.
TABLE 4
__________________________________________________________________________
Volume
Shielding effect
Kneading
Molding
resistivity
in electrical
Experi-
Resin temperature
temperature
value field of 300 MHz
ment No
(kind) (°C.)
(°C.)
(Ω · cm)
(dB)
__________________________________________________________________________
32 ABS 200 220 2.3 × 10.sup.-1
48.9
(Mitsubishi Monsanto Kasei,
trade name: Tuflex 710)
33 Polystyrene 200 220 9.2 × 10.sup.-2
60.0
(produced by Idemitsu
Sekiyu Kagaku, trade
name: SEHI 110)
34 Polybutyleneterephthalate
230 260 2.2 × 10.sup.-1
49.4
(Toray, trade name: PBT-1400L)
35 Polyphenylene oxide
200 220 2.4 × 10.sup.-1
48.4
(Produced by Engineering Plastic
trade name: Noryl 731J-802)
36 Nylon 250 270 2.0 × 10.sup.1
50.1
(Produced by Du Pont, trade
name: Zaitel ST801)
37 Low density polyethylene
120 150 9.5 × 10.sup.-2
59.6
(Produced by Mitsubishi Yuka,
trade name: Yukalon 2F-30)
__________________________________________________________________________
A 70 parts by weight amount of a polypropylene resin (produced by Idemitsu Sekiyu Kagaku, trade name: J-465H), 9 parts by weight of a carbon black with a DBP oil absorption amount of 480 ml/100 g and 21 parts by weight of an expanded graphite with an average particle size of 500 μm were added with additives for resins such as antioxidants for resins, UV-ray absorbers, flame retardants, reinforcing agents, lubricants, etc., shown in Table 5, and kneaded and molded according to the same method as in Example 1. The VR and the shielding effect of the molded products obtained were measured, and the types and amounts of the additives for resins employed, and the measurement results, are shown in Table 5.
TABLE 5
__________________________________________________________________________
Experiment No. 38 39 40 41 42 43 44
Additives for resins
Amount added (wt. parts)
__________________________________________________________________________
Pentaerythrityl-tetrakis 3-(3,5-di-
2.0 2.0 2.0 2.0 2.0 2.0 2.0
tert-butyl-4-hydroxyphenyl)propiolate
Phenylsalicylate 0.1 0 0 0.1 0 0.1 0
2-Hydroxy-4-n-octoxybenzophenone
0.1 0.2 0 0 0 0 0
Trichloroethyl phosphate
0 0 0.1 0.1 0 0 0
Antimony trioxide 5.0 0 0 5.0 0 0 0
Decabromodiphenyl oxide
0 0 5.0 5.0 0 0 0
Zinc stearate 0.5 0.5 0 0 2.0 0 2.0
Ethylene bisstearoamide
0 0 0.5 0 0 0.5 0
Glass fiber 0 15 0 0 15 15 0
Volume resistivity value (Ω · cm)
9.9 × 10.sup.-2
1.3 × 10.sup.-1
9.9 × 10.sup.-2
1.2 × 10.sup.-1
1.3 × 10.sup.-1
1.2 × 10.sup.-1
9.6 ×
10.sup.-2
Shielding effect in electrical field
59.1 55.7 59.2 56.8 55.8 56.8 59.5
of 300 MHz (dB)
__________________________________________________________________________
A thermoplastic resin, carbon black having a DBP oil absorption amount of 480 ml/100 g, expanded graphite, antioxidants for resins, flame retardants, reinforcing agents, lubricants, and plasticizers listed in Tables 6 and 7 were formulated in an amount shown in Tables 6 and 7. The mixture was kneaded and molded in the same manner as in Example 1. The VR and the shielding effect of the molded products obtained were measured. The results are shown in Tables 6 and 7 in relation to the composition of the electroconductive resin.
TABLE 6
__________________________________________________________________________
Experiment No. 45 46 47 48 49 50 51 52
__________________________________________________________________________
Composition of electrocon-
ductive resin (wt. parts)
Polypropylene resin A*.sup.1
72.5 0 0 0 0 0 0 0
Polypropylene resin B*.sup.2
0 72.5 0 0 0 0 0 0
Polypropylene resin C*.sup.3
0 0 48 0 0 0 0 48
Polypropylene resin D*.sup.4
0 0 0 48 48 36 36 0
Polypropylene resin E*.sup.5
0 0 0 0 0 12 12 0
Ethylene-propylene
0 0 10 10 0 10 0 0
rubber A*.sup.6
Ethylene-propylene
0 0 0 0 10 0 10 10
rubber B*.sup.7
Carbon black having DBP oil
11 11 11 11 11 11 11 9
absorption amount of
480 ml/100 g
Expanded graphite having
16.5 16.5 16.5 16.5 16.5 16.5 16.5 21
particle size 5 mm
Talc 0 0 14.5 14.5 14.5 0 0 0
Glass fiber 0 0 0 0 0 14.5 0 14.5
Calcium carbonate
0 0 0 0 0 0 14.5 0
Antioxidant for resin A*.sup. 8
1 1 0 0 0 0 0 0
Antioxidant for resin B*.sup.9
0 0 1 1 1 1 1 1
Ethylenebis hydrogenated
1 1 1 1 1 1 1 1
tallow acid amide
Volume resistivity value
1.1 × 10.sup.-1
1.0 × 10.sup.-1
1.2 × 10.sup.-1
1.2 × 10.sup.-1
1.0 × 10.sup.-1
1.2 × 10.sup.-1
1.2 × 10.sup.-1
1.0 ×
10.sup.-1
(Ω · cm)
Shielding effect in electrical
57.3 58.8 56.4 56.0 57.5 56.2 56.1 57.3
field of 300 MHz (dB)
__________________________________________________________________________
*.sup.1 Karupu Kogyo K. K. 4200G
*.sup.2 Karupu Kogyo K. K. 4560GF
*.sup.3 Idemitsu Petrochemical Co. J5050H
*.sup.4 Idemitsu Petrochemical Co. J465H
*.sup.5 Idemitsu Petrochemical Co. J3066H
*.sup.6 Japan Synthetic Rubber Co. EP07P
*.sup.7 Japan Synthetic Rubber Co. EP912P
*.sup.8 Pentaerythtyltetrakis 3(3,5-di-t-butyl-4-hydroxyphenyl)propiolate
*.sup.9 Pentaerythtyltetrakis
3(3,5-di-t-butyl-4-hydroxyphenyl)propionate/Tris(2,4-di-t-butylphenyl)pho
phite = 50/50
TABLE 7
__________________________________________________________________________
Experiment No. 53 54 55 56 57 58 59 60 61 62
__________________________________________________________________________
Composition of Electroconductive
resin (wt. parts)
6-Nylon resin A*.sup.1
47 0 0 45 0 0 0 0 0 0
6-Nylon resin B*.sup.2
0 47 30 0 0 0 0 0 0 0
6-Nylon resin C*.sup.3
0 0 20 0 0 0 0 0 0 0
High-density polyethylene resin*.sup.4
0 0 0 0 64 48 0 0 0 0
ABS resin*.sup.5 0 0 0 0 0 0 75 72.5
0 0
PBT resin*.sup.6 0 0 0 0 0 0 0 0 47 50
Carbon black having DBP oil absorption
6.9 6.9 7.5 10 10.8
11 10 8.25
6.9 10
amount of 480 ml/100 g
Expanded graphite having average
16.1 16.1
17.5
15 25.2
16.5
15 19.25
16.1
15
particle size of 5 mm
of 5 mm
Butyl benzyl phthalate
0 0 0 0 0 0 5 0 0 0
Antioxidant for resin A*.sup.7
0 0 0 1 0 0 0 0 1 1
Antioxidant for resin B*.sup.8
0 0 0 0 1 1 1 1 0 0
Cuprous iodide 1 1 1 0 0 0 0 0 0 0
Ethylene-propylene rubber A*.sup.9
0 0 0 0 0 10 0 0 0 0
Ethylene-propylene rubber B*.sup.10
0 0 0 5 0 0 0 0 0 10
Antimony trioxide 3.75 3.75
2.5 3.75
0 0 0 0 3.75
0
Decabromo diphenyl ether
11.25
11.25
7.5 11.25
0 0 0 0 11.25
0
Glass fiber 15 15 15 10 0 0 0 0 15 15
Talc 0 0 0 0 0 14.5
0 0 0 0
Ethylenebis hydrogenated tallow acid
1 1 1 0 1 1 1 1 1 1
amide
Benzene sulfonic acid butyl amide
0 0 0 1 0 0 0 0 0 0
Volume resistivity value (Ω · cm)
1.2 ×
1.2 ×
1.0 ×
1.0 ×
8.3 ×
1.3 ×
1.0 ×
1.0 ×
1.1
1.3 ×
10.sup.-1
10.sup.-1
10.sup.- 1
10.sup.-1
10.sup.-2
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
10.sup.-1
Shielding effect in electrical field
56.0 56.5
58.3
58.1
61.3
54.0
57.3
57.5
57.1
54.3
of 300 MHz (dB)
__________________________________________________________________________
*.sup.1 Mitsubishi Chemical Co., 1007J (pellet)
*.sup.2 Mitsubishi Chemical Co., 1007J (Crushed powder having a size of
100-200 μm)
*.sup.3 Mitsubishi Chemical Co., ST145
*.sup.4 Idemitsu Petrochemical Co., 110J
*.sup.5 Japan Synthetic Rubber Co., JSR ABS 35
*.sup.6 Toray Co., PBT1400L
*.sup.7
N,NHexamethylenebis(3,5-di-t-butyl-4-hydroxy-hydrocinnamide)/tris(2,4-di-
-butyl-phenyl)phosphite = 50/50
*.sup.8 Pentaerythtyltetrakis 3(3,5-di-t-butyl-4-hydroxyphenyl)propiolate
*.sup.9 Japan Synthetic Rubber Co., EP07P
*.sup.10 Japan Synthetic Rubber Co., T7741P
Claims (8)
1. An electroconductive resin composition comprising (i) 100 parts by weight of at least one resin selected from the group consisting of thermoplastic resins and thermosetting resins and (ii) 15 to 150 parts by weight of (a) carbon black having a DPB oil absorption amount of 400 ml/100 g to 600 ml/100 g and (b) expanded graphite having an average particle size of 40 μm to 20000 μm, the expanded graphite content being 40 to 90% by weight of the total amount of the carbon black and the expanded graphite.
2. The electroconductive resin composition as claimed in claim 1, wherein the resin is a thermoplastic resin.
3. The electroconductive resin composition as claimed in claim 2, wherein the thermoplastic resin is at least one resin selected from the group consisting of a low, medium or high density polyathylene, linear low density polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, acrylonitrile-butadiene-styrene ternary copolymer, polystyrene, acrylonitrile-styrene copolymer, nitrile rubber, butadiene rubber, styrene-butadiene rubber, ethylene-propylene-diene rubber, silicone rubber, thermoplastic polyurethane resin, polyamide resin, polyester resin, polycarbonate, polyvinyl chloride, polyacetal resin, polyphenylene sulfite, and polyphenylene oxide.
4. The electroconductive resin composition as claimed in claim 1, wherein the resin is a thermosetting resin.
5. The electroconductive resin composition as claimed in claim 4, wherein the thermosetting resin is at least one resin selected from the group consisting of thermosetting acrylic resins, phenol resins, unsaturated polyester resins, epoxy resins, urethane resins, and alkyd resins.
6. The electroconductive resin composition as claimed in claim 1, wherein the total amount of the carbon black and the expanded graphite is 20 to 130 parts by weight based on 100 parts by weight of the resin.
7. The electroconductive resin composition as claimed in claim 1, wherein the amount of the expanded graphite is 45% to 85% by weight of the total amount of the carbon black and the expanded graphite.
8. The electroconductive resin composition as claimed in claim 1, in which said composition is characterized with an electroconductivity of 1Ω·cm or lower.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP62165749A JPH0813902B2 (en) | 1987-07-02 | 1987-07-02 | Conductive resin composition |
| JP62-165749 | 1987-07-02 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US4971726A true US4971726A (en) | 1990-11-20 |
Family
ID=15818345
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US07/213,264 Expired - Fee Related US4971726A (en) | 1987-07-02 | 1988-06-29 | Electroconductive resin composition |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4971726A (en) |
| EP (1) | EP0297888B1 (en) |
| JP (1) | JPH0813902B2 (en) |
| AT (1) | ATE84901T1 (en) |
| DE (1) | DE3877635T2 (en) |
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Also Published As
| Publication number | Publication date |
|---|---|
| EP0297888A1 (en) | 1989-01-04 |
| DE3877635T2 (en) | 1993-06-03 |
| JPH0813902B2 (en) | 1996-02-14 |
| ATE84901T1 (en) | 1993-02-15 |
| EP0297888B1 (en) | 1993-01-20 |
| JPS6411161A (en) | 1989-01-13 |
| DE3877635D1 (en) | 1993-03-04 |
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